Multicolor carpet and method of making same

ABSTRACT

A multicolor carpet comprising a plurality of tufted yarns, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein at least one of the yarns is of a different color than any of the other yarns, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

FIELD OF THE INVENTION

The invention relates to multicolor carpets formed from solution-dyed,BCF fibers.

BACKGROUND OF THE INVENTION

Polymers have long been the most prevalent material used for formingyarns for use in the carpet industry. Therefore, there is a continuinginterest to develop less costly and more environmentally friendlymethods of carpet production.

Multicolor carpets are widely used to provide consumers with variousdesign options for flooring designs. These carpets are typically formedfrom direct tufted, white acid dyeable staple fibers. Colors are printedon theses carpets after the carpet fibers are tufted. Printed carpets donot have sharp color registration, acceptable stain resistance and goodcolor fastness. Some direct tufted nylon carpets are sold as floorcoverings in automotive interiors, mainly in solid colors. However, dueto bonding issues, antistatic fiber cannot be used in automotivecarpeting. For these reasons, direct tuft carpets have not found broadacceptance for residential or commercial markets.

Carpets that are suitable for use for residential purposes typicallyrequire additional process steps to meet the necessary qualitystandards. Residential carpet processing consists of many stepsincluding cable twisting, heatsetting, dyeing and applying low pH stainblock chemicals. These steps are costly and unfriendly to theenvironment due to extensive consumption of energy, water, steam and lowpH chemicals. Cable twisting and heatsetting are required to makeaesthetically attractive carpets with good tip definition. However, thetip definition of cable twisted carpets deteriorates with traffic due totwist unrevealing that results in worn out look.

Therefore, there is a need for multicolor carpets with improved stainresistance and color fastness that also meet the quality standardsnecessary for residential and commercial markets.

SUMMARY OF THE INVENTION

The present invention relates to a multicolor carpet that is directtufted and meets the quality standards needed for use in residential andcommercial markets. The multicolor carpets of the current inventioneliminate costly and environmentally unfriendly steps typicallynecessary for carpets that are sold into the residential and commercialflooring markets. These eliminated steps can include, twisting,heatsetting, dyeing and downstream wet processing.

In one nonlimiting aspect of the present invention, a multicolor carpetis disclosed comprising a plurality of tufted yarns of at least twodifferent colors, wherein the yarns comprise solution-dyed bulkedcontinuous filaments, wherein the yarns have not been twisted, andwherein the yarns have not been heatset.

In another nonlimiting aspect of the present invention, a multicolorcarpet is disclosed comprising a plurality of tufted yarns of at leasttwo different colors, wherein the yarns comprise solution-dyed bulkedcontinuous filaments, wherein the solution-dyed bulked continuousfilaments further comprises an aromatic sulfonate or an alkali metalsalt thereof, wherein the yarns have not been twisted, and wherein theyarns have not been heatset.

In another nonlimiting aspect of the present invention, a multicolorcarpet is disclosed comprising a plurality of tufted yarns of at leasttwo different colors, wherein the yarns comprise solution-dyed bulkedcontinuous filaments, wherein the solution-dyed bulked continuousfilaments further comprises an aromatic sulfonate or an alkali metalsalt thereof, wherein the plurality of tufted yarns further comprises atleast one conductive filament , wherein the yarns have not been twisted,wherein the yarns have not been heatset.

In another embodiment aspect of the present invention, a method ofmaking a multicolor carpet is disclosed, wherein the method comprisesthe step of tufting a plurality of yarns of at least two differentcolors to form a carpet, wherein the yarns comprise solution-dyed bulkedcontinuous filaments, wherein the yarns have not been twisted, andwherein the yarns have not been heatset.

In another nonlimiting aspect of the present invention, an article ofmanufacture is disclosed, at least a portion of which comprises amulticolor carpet comprising a plurality of tufted yarns of at least twodifferent colors, wherein the yarns comprise solution-dyed bulkedcontinuous filaments, wherein the yarns have not been twisted, andwherein the yarns have not been heatset.

In another nonlimiting aspect of the present invention, an article ofmanufacture is disclosed, at least a portion of which comprises, amulticolor carpet comprising a plurality of tufted yarns of at least twodifferent colors, wherein the yarns comprise solution-dyed bulkedcontinuous filaments, wherein the solution-dyed bulked continuousfilaments further comprises an aromatic sulfonate or an alkali metalsalt thereof, wherein the yarns have not been twisted, and wherein theyarns have not been heatset.

In another nonlimiting aspect of the present invention, an article ofmanufacture is disclosed, at least a portion of which comprises, amulticolor carpet comprising a plurality of tufted yarns of at least twodifferent colors, wherein the yarns comprise solution-dyed bulkedcontinuous filaments, wherein the solution-dyed bulked continuousfilaments further comprises an aromatic sulfonate or an alkali metalsalt thereof, wherein the plurality of tufted yarns further comprises atleast one conductive filament , wherein the yarns have not been twisted,and wherein the yarns have not been heatset.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A and FIG. 1B are images of multicolor carpets of the currentinvention.

FIG. 2A, FIG. 2B and FIG. 2C are images of multicolor carpets of thecurrent invention.

FIG. 3A and FIG. 3B are images of multicolor carpets of the currentinvention.

DETAILED DESCRIPTION OF THE INVENTION

Provided by the present invention are multicolor carpets comprising aplurality of tufted yarns of at least two different colors, wherein theyarns have not been twisted, and wherein the yarns have not beenheatset. Also provided is a method for production of carpets andarticles of manufacture, at least a portion of which comprise themulticolor carpets disclosed herein.

It is common for carpet that is used for residential or commercialpurposes to be twisted, heatset and be subjected to downstream wetprocessing to achieve desirable properties. The multicolor carpets ofthe current invention are not subjected to a twisting step, such as plytwisting or cable twisting, or a heatsetting step which give a tuftedcarpet tip definition. Downstream wet processing steps can includedyeing, and the application of stain resist or soil resist chemistries.Contrary to what would be expected, the inventors have found thatmulticolor carpets of the current invention can be produced withsatisfactory aesthetics, wear performance and staining properties.Furthermore, the multicolor carpets of the current invention simulatethe appearance of twisted and heatset yarns in tufted fabrics, withoutbeing subjected to twisting, heatsetting or any downstream wetprocessing after tufting.

Without being bound by any particular theory, it is believed that inorder to achieve a multicolor carpet with satisfactory aesthetics theyarn used must be smooth and have good interlace without containing alarge number of interlace nodes. Interlace nodes with a diameter lessthan 30% of the main yarn body are considered to be severe tightinterlace nodes. Interlace nodes with a diameter less than 50% of themain yarn body are considered to be moderate interlace nodes. In onenonlimiting embodiment of the current invention, the multicolor carpetsare formed from solution dyed BCF yarns that contain less than 5 severeinterlace nodes per meter and less than 30 moderate interlace nodes permeter. In another nonlimiting embodiment of the current invention,multicolor carpets are formed from solution dyed BCF yarns that areessentially free of severe interlace nodes. In another nonlimitingembodiment of the current invention, the multicolor carpets are formedfrom solution dyed BCF yarns that contain less than 20 moderateinterlace nodes per meter. The number of moderate and severe interlacenodes are determined by visual inspection according to the NodeEvaluation Procedure, defined below.

The multicolor carpets of the current invention can be formed in variouscarpet constructions that are known in the industry. In one nonlimitingembodiment of the current invention, the multicolor carpets have a pileheight of 0.5 inches or less. In another nonlimiting embodiment of thecurrent invention, the multicolor carpets have a pile height of 0.375inches or less. In one nonlimiting embodiment of the current invention,the multicolor carpets have a face weight in the range of about 12 toabout 50 ounces per yard. In another nonlimiting embodiment of thecurrent invention, the multicolor carpets have face weight in the rangeof about 18 to about 40 ounces per yard.

The multicolor carpets of the current invention can be formed from yarnsof denier and filament count that that are known for use in carpetmanufacturing. In nonlimiting embodiments of the current invention, theyarns comprise solution-dyed bulked continuous filaments (BCF) yarns. Inone nonlimiting embodiment of the current invention, the yarns have adenier in the range from about 500 denier to about 3000 denier. Inanother nonlimiting embodiment of the current invention, the yarns havea denier in the range from about 1100 denier to about 1800 denier.

The multicolor carpets of the current invention can be formed from yarnsfrom a plurality of colors. In one nonlimiting embodiment of the currentinvention, the multicolor carpets comprise between 2 to 8 differentcolor yarns. In nonlimiting embodiments, yarns may comprise filaments ofat least 2 different colors.

In one nonlimiting embodiment of the current invention, the multicolorcarpet is comprised of a plurality of tufts, wherein each tuft iscomprised of at least one tufted yarn. In another nonlimiting embodimenteach tuft is comprised of tufted yarn of a single color.

Without being bound any particular theory, it is believed that thepatterns formed from the use of different color yarns create the colordefinition necessary for the multicolor carpets to have an acceptableaesthetic look that is comparable to carpets formed from yarns that havebeen subjected to several additional texturing steps. To maximize thecolor definition in the multicolor carpet, the use of a single coloryarn over large areas of the carpet should be minimized. For a two colorcarpet an ABAB thread up can be used. For a three color carpet an ABCABCthread up can be used. For a four color carpet an AB, CD two ends perneedle thread up can be used.

In one nonlimiting embodiment of the current invention, the majority oftufts are immediately adjacent to at least one other tuft comprised oftufted yarn of at least one different color. In another nonlimitingaspect, each tuft is immediately adjacent to at least one other tuftcomprised of tufted yarn of at least one different color. In anothernonlimiting embodiment of the current invention, there is no 12 squareinch area of the carpet covered by yarns of only a single color. Inanother nonlimiting embodiment, there is no 4 square inch area of thecarpet covered by yarns of only a single color. In yet anothernonlimiting embodiment of the current invention, there is no singlesquare inch area of the carpet that is covered by yarns of only a singlecolor.

The multicolor carpets of the present invention also exhibit excellentdurability. In one nonlimiting embodiment of the current invention, thecarpet has an appearance rating of at least 3 when subjected to a walktest according to ASTM D6119. In another nonlimiting embodiment of thecurrent invention, the carpet has an appearance rating of at least 4.5when subjected to a walk test according to ASTM D6119.

In a nonlimiting embodiment of the current invention, the multicolorcarpet of the current invention may be comprised of bulked continuousfilaments formed from solution-dyed polyamide polymer. Suitablepolyamides include fiber forming polyamides known in the art to besuitable for the formation of bulked continuous filament fibers, havingsufficient viscosity, tenacity, chemical stability and crystalinity tobe at least moderately durable in such application. The at least onepolyamide resin may be selected from the group consisting of nylon 5,6;nylon 6/6; nylon 6; nylon 7; nylon 11; nylon 12; nylon 6/10;, nylon6/12; nylon DT; nylon 6T; nylon 61; and blends or copolymers thereof. Inone embodiment, the solution-dyed bulked continuous filaments are formedfrom nylon 6,6 polymer.

In another nonlimiting embodiment, the solution-dyed bulked continuousfilaments are formed from aliphatic carbon filaments, especiallypolypropylene.

Suitable polyesters include fiber forming polyesters known in the art.The at least one polyester resin may be selected from the groupconsisting of polyethylene terephthalate, polytrimethyleneterephthalate, polybutylene terephthalate, polyethylene naphthalate,polylactic acid (PLA) and blends or copolymers thereof.

In embodiments of the current invention, the solution-dyed bulkedcontinuous filaments of the multicolor carpet further comprise acationic dye additive. The use of cationic dye additives inthermoplastics has been discussed in U.S. Pat. No. 5,108,684 to Anton,herein incorporated by reference. The use of cationic dye additivesimpart stain resistant properties to the yarns used in the currentinvention. Suitable cationic dye additives which may be used includethose aromatic sulfonates and their alkali metal salts which are capableof copolymerizing with the polymeric raw materials used to form thesolution dyed bulk continuous filaments of the current invention. In onenonlimiting embodiment of the current invention, the cationic dyeadditive is 5-sulfoisophthalate. In another nonlimiting embodiment, the5-sulfoisophthalate in the solution-dyed bulked continuous filaments isin the range of about 1 to about 8 percent by weight. In anothernonlimiting embodiment, the 5-sulfoisophthalate in the solution-dyedbulked continuous filaments is in the range of about 1 to about 4percent by weight. In one nonlimiting embodiment of the currentinvention, the multicolor carpet has a stain rating of at least 5. Inanother nonlimiting embodiment of the current invention, the carpet hasa stain rating of about 10.

In one nonlimiting embodiment of the current invention, the plurality oftufted yarns used in the multicolor carpet further comprises at leastone conductive filament. In another nonlimiting embodiment, the amountof conductive filaments is sufficient to form an antistatic carpet.Examples of conductive filaments that can be used to impart antistaticproperties to a carpet were disclosed in U.S. Pat. Nos. 4,900,495 and4,997.712, herein incorporated by reference. In one nonlimitingembodiment of the current invention, the conductive filaments is spinorientated and has a nonconductive polymeric component coextensive witha component of electrically conductive carbon dispersed in a polymericmatrix wherein the nonconductive polymeric component of thespin-oriented, conductive filaments is a melt-blend containing a majoramount of a nonconductive, fiber-forming polymeric material.

The present invention also provides for a method of manufacturing amulticolor carpet. In this method, a plurality of yarns of at least twodifferent colors are tufted to form a carpet, wherein the yarns comprisesolution-dyed, bulked continuous filaments, wherein the yarns have notbeen twisted, and wherein the yarns have not been heatset.

Also provided by the present invention are articles of manufacture, atleast a portion of which comprises a multicolor carpet comprising aplurality of tufted yarns of at least two different colors, wherein theyarns comprise solution-dyed bulked continuous filaments, wherein theyarns have not been twisted, and wherein the yarns have not beenheatset.

Also provided by the present invention are articles of manufacture, atleast a portion of which comprises, a multicolor carpet comprising aplurality of tufted yarns of at least two different colors, wherein theyarns comprise solution-dyed bulked continuous filaments, wherein thesolution-dyed bulked continuous filaments further comprises an aromaticsulfonate or an alkali metal salt thereof, wherein the yarns have notbeen twisted, and wherein the yarns have not been heatset.

Also provided by the present invention are articles of manufacture, atleast a portion of which comprises, a multicolor carpet comprising aplurality of tufted yarns of at least two different colors, wherein theyarns comprise solution-dyed bulked continuous filaments, wherein thesolution-dyed bulked continuous filaments further comprises an aromaticsulfonate or an alkali metal salt thereof, wherein the plurality oftufted yarns further comprises at least one conductive filament ,wherein the yarns have not been twisted, and wherein the yarns have notbeen heatset.

Definitions

BCF—Bulked Continuous Filament

SIPA—sulfonated isophthalic acid

Test Methods

Walk Test: The durability of the carpet was measured by the walk testunder ASTM D6119 for creating surface appearance changes in pile yarnfloor covering form foot traffic.

Stain Resistance Test: Acid dye stain resistance is evaluated using aprocedure modified from the American Association of Textile Chemists andColorists (AATCC) Method 175-2003, “Stain Resistance: Pile FloorCoverings.” 9 wt % of aqueous staining solution is prepared, accordingto the manufacturer's directions, by mixing cherry-flavored KOOL-AID®powder (Kraft/General Foods, White Plains, N.Y., a powdered drink mixcontaining, inter alia, FD&C Red No. 40). A carpet sample (4×6-inch) isplaced on a flat non-absorbent surface. A hollow plastic 2-inch (5.1 cm)diameter cup is placed tightly over the carpet sample. Twenty mL of theKOOL-AID® staining solution is poured into the cup and the solution isallowed to absorb completely into the carpet sample. The cup is removedand the stained carpet sample is allowed to sit undisturbed for 24hours. Following incubation, the stained sample is rinsed thoroughlyunder cold tap water, excess water is removed by centrifugation, and thesample is dried in air. The carpet sample was visually inspected andrated for staining according to the FD&C Red No. 40 Stain Scaledescribed in AATCC Method 175-2003. Stain resistance is measured using a1-10 scale. An undetectable test staining is accorded a value of 10.Ratings are determined by visual examination by a panel of evaluators.

Node Evaluation Procedure: The frequency of nodes formed by the process,and the tightness of the discrete nodes formed, were determined byvisual observation. Typically, a length of yarn as provided by theprocess is hung vertically, with no tension applied. The length of yarnis 2.5-3 meters. Then, the number of moderate and severe interlacenodes, in the form of entangled or compacted regions, are counted alongthe length of the yarn. A moderate interlace node is adjudged to have ayarn diameter of less than 50% of the main yarn body. A severe interlacenode is adjudged to have a diameter of less than 30% of the main yarnbody. The routine is repeated for 4-5 more yarn segments representativea given sample, and the values determined used to provide an averagenumber of moderate and severe interlace nodes for a given sample ofyarn.

The SDN BCF yarns used to make the multicolor carpets of the currentinvention contain less than 5 severe interlace nodes per meter andtypically, no severe interlace nodes are observed. SDN BCF yarns made bythis process used in the current invention comprise less than 30moderate interlace nodes. In other aspects of the current invention, theSDN BCF yarns comprise less than 20 moderate interlace per meter.

EXAMPLES

The following Examples demonstrate the present invention and itscapability for use. The invention is capable of other and differentembodiments, and its several details are capable of modifications invarious apparent respects, without departing from the scope and spiritof the present invention. Accordingly, the Examples are to be regardedas illustrative in nature and non-limiting.

Example 1 (Comparative)

Two ends of 1500 denier, 6.5 dpf solution dyed BCE yarn were ply twistedtogether (3.25 turns per inch) on a Volkman twisting machine. Both BCFused in this example were earth tone color yarns with slightly differentshade (code as western sand and sand dune). The cable twisted yarn washeatset on Superba at 265 F and converted into 0.5 inch pile height, 18oz/yd. cut pile carpet on a 5/32 gauge tufting machine, a typicalconstruction for low weight residential carpet.

The finished carpets was stained with Kool-aid for 24 hours, rinsed withwater and judged by a panel of experts to have a stain rating of 6 in a1 to 10 scale. This sample failed the STAINMASTER® stain protectionrequirement.

This carpet sample was also tested for newness retention in a Vettermandrum. After 5000 cycles, this sample had a severe worn out pattern andwas rated by a panel of experts to be unacceptable as brandedSTAINMASTER® carpet.

Example 2 (Comparative)

A 1500 denier, 6.5 dpf medium earth tone color solution dyed BCF yarnwas tufted into a 18 oz/yd. ¼″ pile height cut pile carpet on a 1/12gauge M-tufting machine. The finished solid color carpet had no tipdefinition and rated by a panel of experts to be aestheticallyunacceptable for residential carpet.

Example 3 (Current Invention)

Three 1500 denier 6.5 dpf light, medium and dark earth tone solutiondyed BCF yarns, after having passed the Node Evaluation Procedure, werealternately tufted into a 18 oz/yd. multicolor ¼″ pile height cut pilecarpet on a 1/12 gauge M-tufting machine. The finished carpet had adifferent colored yarn tuft separating it in each direction from anyother yarn tuft of the same color, and none of the yarns of the carpetwere either twisted or heat set. Overall the carpet gave an attractiveappearance. The mixture of colors in adjacent tufts gives a pseudo tipdefinition that was similar to the tip definition created by cable twistand heatset carpets.

The finished carpets was stained with Kool-aid for 24 hours, rinsed withwater and judged by a panel of experts to have a stain rating of 10 in a1 to10 scale. This sample passed the STAINMASTER® stain protectionrequirement.

This carpet sample was also tested for newness retention in a Vettermandrum. After 5000 cycles, this sample had no worn out or crushed pattern.The tested carpet had the exact same look as the untested carpet.

Example 4 (Current Invention)

Three 1500 denier 6.5 dpf light, medium and dark earth tone solutiondyed BCF yarn, after having passed the Node Evaluation Procedure, werealternately tufted into a 22 oz/yd. multicolor ¼″ pile height loop pilecarpet on a 5/64 gauge M--tufting machine. The finished carpet had anattractive appearance.

The finished carpets was stained with Kool-aid for 24 hours, rinsed withwater and judged by a panel of experts to have a stain rating of 10 in a1 to 10 scale. This sample passed the STAINMASTER® stain protectionrequirement.

This carpet sample was also tested for newness retention in a Vettermandrum. After 5000 cycles, this sample had no worn out pattern. The testedcarpet had the exact same look as the untested carpet.

Example 5 (Current Invention)

1500 denier, 13 dpf solution dyed BCF yarn made from cationic dyeablepolymer and, after having passed the Node Evaluation Procedure, weretufted on a 1/10 gauge tufting machine (color point by Card-MonroeCorporation). Two color light weight carpets (19 oz/yds. 10/32 inch pileheight, 10 stitches per inch) with various patterns and colorcombinations were successfully produced without any processing issue.The finished carpets had an attractive appearance. The multicolorcarpets formed from these yarns are depicted in FIGS. 1A and 1B.

The finished carpets were stained with Kool-aid for 24 hours, rinsedwith water and judged by a panel of experts to have a stain rating of 10in a 1 to 10 scale. These samples passed the STAINMASTER® stainprotection requirement.

These carpet samples were also tested for newness retention in aVetterman drum. After 5000 cycles, this sample had no visible worn outpattern.

Example 6 (Current Invention)

1500 denier, 13 dpf solution dyed BCF yarns made from cationic dyeablepolymer and having passed the Node Evaluation Procedure were tufted on a1/10 gauge tufting machine (color point by Card-Monroe Corporation).Three color light weight carpets (19 oz/yds. 10/32 inch pile height, 10stitches per inch) with various patterns and color combinations weresuccessfully produced without any processing issue. The finished carpetshad an attractive appearance. The multicolor carpets formed from theseyarns are depicted in FIGS. 2A, 2B and 2C.

The finished carpets were stained with Kool-aid for 24 hours, rinsedwith water and judged by a panel of experts to have a stain rating of 10in a 1 to 10 scale. These samples passed the STAINMASTER® stainprotection requirement.

These carpet samples were also tested for newness retention in aVetterman drum. After 5000 cycles, this sample had no visible worn outpattern.

Example 7 (Current Invention)

997 denier, 9 dpf solution dyed Nylon 66 BCF yarns made from cationicpolymer and having passed the Node Evaluation Procedure were used forthis example. In one case, two earth tone color yarns (western sand,color A, antique white, color B) were used in odd number needles andother two earth tone color yarns (Indian pottery color C, sand dunecolor D) were used in even number needles on a 1/10 gauge CMC colorpoint tufting machine. Medium weight carpets (26 oz, ⅜″ pile height, 10stitched per inch) were successfully produced without any tufting issue.This sample was subject to 20,000 cycle walk test (ASTM D6119) atProfessional test lab in Dalton Georgia. The rating was 3.5. It wasconsidered as a good performing carpet. The multicolor carpet formedfrom these yarns is depicted in FIG. 3A.

In another case, two grayish color yarns (Woodsmock, Burmese gray) wereused in odd number needles and another two grayish color yarns(mineshaft, pearl) were used in even number needles on a 1/10 gauge CMCcolor point tufting machine. Medium weight carpet (32 oz, ⅜″ pileheight, 10 stitches per inch) were successfully produced without anyprocessing issues. The multicolor carpet formed from these yarns isdepicted in FIG. 3B.

This sample was subjected to 20,000 cycle walk test at ProfessionalTesting Laboratory, Inc. (Dalton, Ga.). The rating was 4.5, which ratesthe sample as a superior performing carpet.

Example 8 (Current Invention)

A 1800 denier 90 filament tri-color Nylon 6 BCF yarn was made on Neumag3+ spinning machine. This yarn as spun, had 30 filaments each of black,gray and white color filaments. This yarn was tufted on a ⅛ gauge cutpile tufting machine to form a 18 oz/yd. 10/32 inch pile height, 10stitch per inch cut pile carpet. It had an appearance of near solidcolor carpet but with interesting light, medium and dark toner effect.

Example 9 (Current Invention)

A 1800 denier 102 filament tri-color polyester BCF yarn was made onNeumag S+spinning machine. This yarn as spun, had 34 filaments each ofblack, dark brown and white color filaments. This yarn was tufted on a ⅛gauge cut pile tufting machine to form a 18 oz/yd. 10/32 inch pileheight, 10 stitch per inch cut pile carpet. It had an appearance of nearsolid color carpet but with interesting light, medium and dark tonereffect.

It should be noted that ratios, concentrations, amounts, and othernumerical data may be expressed herein in a range format. It is to beunderstood that such a range format is used for convenience and brevity,and thus, should be interpreted in a flexible manner to include not onlythe numerical values explicitly recited as the limits of the range, butalso to include all the individual numerical values or sub-rangesencompassed within that range as if each numerical value and sub-rangeis explicitly recited. To illustrate, a concentration range of “about0.1% to about 5%” should be interpreted to include not only theexplicitly recited concentration of about 0.1 wt % to about 5 wt %, butalso the individual concentrations (e.g., 1%, 2%, 3%, and 4%) and thesub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the indicatedrange. The term “about” can include ±1%, ±2%, ±3%, ±4%, ±5%, ±8%, or±10%, of the numerical value(s) being modified. In addition, the phrase“about ‘x’ to ‘y’” includes “about ‘x’ to about ‘y’”.

While the illustrative embodiments of the invention have been describedwith particularity, it will be understood that the invention is capableof other and different embodiments and that various other modificationswill be apparent to and may be readily made by those skilled in the artwithout departing from the spirit and scope of the invention.Accordingly, it is not intended that the scope of the claims hereof belimited to the examples and descriptions set forth herein but ratherthat the claims be construed as encompassing all the features ofpatentable novelty which reside in the present disclosure, including allfeatures which would be treated as equivalents thereof by those skilledin the art to which the invention pertains.

1. A multicolor carpet comprising a plurality of tufted yarns of atleast two different colors, wherein the yarns comprise solution-dyedbulked continuous filaments, wherein the yarns have not been twisted,and wherein the yarns have not been heatset.
 2. The multicolor carpet ofclaim 1 wherein the carpet has an appearance rating of at least 3 whensubjected to a walk test according to ASTM D6119.
 3. The multicolorcarpet of claim 1 wherein the carpet has not been subjected to anydownstream wet processing after tufting.
 4. The multicolor carpet ofclaim 1 wherein yarns contain less than 30 moderate interlace nodes permeter.
 5. The multicolor carpet of claim 1 wherein yarns contain lessthan 20 moderate interlace nodes per meter.
 6. The multicolor carpet ofclaim 1 wherein yarns contain less than 5 severe interlace nodes permeter.
 7. The multicolor carpet of claim 1 wherein the carpet has a pileheight of 0.5 inches or less.
 8. The multicolor carpet of claim 1wherein the carpet has a pile height of 0.375 inches or less.
 9. Themulticolor carpet of claim 1 wherein the carpet has a face weight inrange of about 12 to about 50 ounces per yard.
 10. The multicolor carpetof claim 1 wherein the carpet has a face weight in range of about 18 toabout 40 ounces per yard.
 11. The multicolor carpet of claim 1 whereinthe carpet comprises between 2 to 8 different color yarns.
 12. Themulticolor carpet of claim 1 wherein the yarns are comprised of aplurality of filaments, and wherein at least a portion of the yarns arecomprised of filaments of at least two different colors.
 13. Themulticolor carpet of claim 1 wherein the carpet is comprised of aplurality of tufts, wherein each tuft is comprised of at least onetufted yarn.
 14. The multicolor carpet of claim 13 wherein the majorityof tufts are immediately adjacent to at least one other tuft comprisedof tufted yarn of at least one different color.
 15. The multicolorcarpet of claim 13 wherein each tuft is immediately adjacent to at leastone other tuft comprised of tufted yarn of at least one different color.16. The multicolor carpet of claim 1 wherein there is no 12 square incharea of the carpet covered by yarns of only a single color.
 17. Themulticolor carpet of claim 1 wherein there is no 4 square inch area ofthe carpet covered by yarns of only a single color.
 18. The multicolorcarpet of claim 1 wherein there is no single square inch area of thecarpet covered by yarns of only a single color.
 19. The multicolorcarpet of claim 1 wherein the solution-dyed bulked continuous filamentsare formed from filaments selected from the group consisting ofpolyamides, polypropylenes, polyesters and copolymers and blendsthereof.
 20. The multicolor carpet of claim 1 wherein the solution-dyedbulked continuous filaments are formed from nylon 6,6 filaments.
 21. Themulticolor carpet of claim 1 wherein the solution-dyed bulked continuousfilaments further comprises an aromatic sulfonate or an alkali metalsalt thereof.
 22. The multicolor carpet of claim 21 wherein the carpethas a stain rating of at least
 5. 23. The multicolor carpet of claim 21wherein the carpet has a stain rating of about
 10. 24. The multicolorcarpet of claim 21 wherein the aromatic sulfonate is5-sulfoisophthalate.
 25. The multicolor carpet of claim 1 wherein theplurality of tufted yarns further comprises at least one conductivefilament.
 26. The multicolor carpet of claim 25 wherein the amount ofconductive filaments is sufficient to form an antistatic carpet.
 27. Amulticolor carpet comprising a plurality of tufted yarns, wherein theyarns comprise solution-dyed bulked continuous filaments, wherein thesolution-dyed bulked continuous filaments further comprises an aromaticsulfonate or an alkali metal salt thereof, wherein at least one of theyarns is of a different color than any of the other yarns, wherein theyarns have not been twisted, and wherein the yarns have not beenheatset.
 28. A multicolor carpet comprising a plurality of tufted yarns,wherein the yarns comprise solution-dyed bulked continuous filaments,wherein the solution-dyed bulked continuous filaments further comprisesan aromatic sulfonate or an alkali metal salt thereof, wherein at leastone of the yarns is of a different color than any of the other yarns,wherein the plurality of tufted yarns further comprises at least oneconductive filament , wherein the yarns have not been twisted, andwherein the yarns have not been heatset.
 29. The method of making amulticolor carpet comprising the step of tufting a plurality of yarns toform a carpet, wherein the yarns comprise solution-dyed bulkedcontinuous filaments, wherein at least one of the yarns is of adifferent color than any of the other yarns, wherein the yarns have notbeen twisted, and wherein the yarns have not been heatset.
 30. Themethod of claim 29 wherein the carpet has an appearance rating of atleast 3 when subjected to a walk test according to ASTM D6119.
 31. Themethod of claim 29 wherein the carpet has not been subjected to anydownstream wet processing after tufting.
 32. The method of claim 29wherein yarns contain less than 30 moderate interlace nodes per meter.33. The method of claim 29 wherein yarns contain less than 5 severeinterlace nodes per meter.
 34. The method of claim 29 wherein the carpethas a pile height of 0.5 inches or less.
 35. The method of claim 29wherein the carpet has a face weight in range of about 12 to about 50ounces per yard.
 36. The method of claim 29 wherein the carpet comprisesbetween 2 to 8 different color yarns.
 37. The method of claim 29 whereinthe yarns are comprised of a plurality of filaments, and wherein atleast a portion of the yarns are comprised of filaments of at least twodifferent colors.
 38. The method of claim 29 wherein the carpet iscomprised of a plurality of tufts, wherein each tuft is comprised of atleast one tufted yarn.
 39. The method of claim 38 wherein the majorityof tufts are immediately adjacent to at least one other tuft comprisedof tufted yarn of at least one different color.
 40. The method of claim38 wherein each tuft is immediately adjacent to at least one other tuftcomprised of tufted yarn of at least one different color.
 41. The methodof claim 29 wherein there is no 12 square inch area of the carpetcovered by yarns of only a single color.
 42. The method of claim 29wherein there is no 4 square inch area of the carpet covered by yarns ofonly a single color.
 43. The method of claim 29 wherein there is nosingle square inch area of the carpet covered by yarns of only a singlecolor.
 44. The method of claim 29 wherein the solution-dyed bulkedcontinuous filaments are formed from filaments selected from the groupconsisting of polyamides, polypropylenes, polyesters and copolymers andblends thereof.
 45. The method of claim 29 wherein the solution-dyedbulked continuous filaments are formed from nylon 6,6 filaments.
 46. Themethod of claim 29 wherein the solution-dyed bulked continuous filamentsfurther comprises an aromatic sulfonate or an alkali metal salt thereof.47. The method of claim 46 wherein the carpet has a stain rating of atleast
 5. 48. The method of claim 46 wherein the aromatic sulfonate is5-sulfoisophthalic acid.
 49. The method of claim 29 wherein theplurality of tufted yarns further comprises at least one conductivefilament.
 50. The method of claim 49 wherein the amount of conductivefilaments is sufficient to form an antistatic carpet.
 51. An article ofmanufacture, at least a portion of which comprises the multicolor carpetof any of claims 1 through 50.